Wind resistant concrete roof component and system and method for forming same

ABSTRACT

A roof system includes a roof panel formed of concrete and an architectural surface such as a corrugated surface. A first layer of reinforcing material is disposed along and spaced inwardly from a first surface of the roof panel, and an optional second layer of reinforcing material is disposed along and spaced inwardly from a second surface of the roof panel. The first layer of reinforcing material is spaced from the second layer of reinforcing material. The reinforcing material may be formed of fiber-reinforced polymer mesh, made with carbon fibers or glass fibers. FRP rebar may be used in conjunction with FRP mesh to provide added structural strength. The roof panel may include one or more elongated ribs having a thickness greater than adjacent portions of the roof panel. In other aspects, concrete structures with reinforcing material may be used for either roof panels or wall applications.

RELATED APPLICATIONS

This application is a continuation application of U.S. patentapplication Ser. No. 14/133,009, filed Dec. 18, 2013, which claimspriority benefit of provisional application No. 61/738,918, filed Dec.18, 2012, the entirety of U.S. patent application Ser. Nos. 14/133,009and 61/738,918 are hereby incorporated by reference herein.

FIELD OF THE INVENTION

The present invention relates generally to a roof component such as aroof panel and a roof system including one or more of the roof panels,and a method of forming same.

DESCRIPTION OF THE BACKGROUND

A high growth in hurricane-induced losses in recent years is asignificant concern for coastal communities. Low-rise buildings,including residential structures, institutional structures, andcommercial structures, are believed to be a dominant building type inthe United States and also seem to be among the most vulnerable underhigh winds, such as those occur during hurricanes, tropical storms, etc.Recent post-disaster surveys have provided direct evidence thathurricane-induced damage and property losses are caused in large partdue to failure of roofs and subsequent intrusion of water into abuilding.

Wind damage to buildings principally manifests in breach of the roofenvelope and/or the wall envelope, and consequent damage to the buildingcontents. Hence, the vulnerability of buildings to high winds is afunction of the loading and the strength of building envelope componentsand their connections. Also, for a given building impacted by winds of agiven intensity, the resulting damage is largely dependent upon thenature of its immediate environment and the architectural design of thebuilding.

Extreme wind events are responsible for significant property damage andloss of life due to compromised residential homes. Hurricanes, forexample, create massive destruction, and the damage from the windpressure, wind borne debris, storm surge, and flooding cause high lossesover a short period of time. Coastal areas in the United States alongthe Atlantic and Pacific Oceans and the Gulf of Mexico are particularlysusceptible to this type of damage. Other extreme wind events mayinclude tornados, high straight line wind storms, and typhoons, alongwith katabatic winds, such as the Santa Ana winds in California.

If the building envelope is compromised, the whole structure is put injeopardy, because internal pressure results. While wind pressure createshigh forces, especially near the edges of the structure, wind bornedebris can also compromise the structure. The roof system of thebuilding is particularly of interest because the construction methodscreate a component of the overall structure that is a potentially weakerpoint.

For example, damage investigation following Hurricane Andrew in 1992 andother more recent events found that many building structures were notdestroyed because of the external wind-pressure load alone. Flyingdebris frequently breached the windward elements of the buildingenvelopes and subjected the building interior to intense fluctuations ofpositive pressure. However, fluctuating negative pressure on exteriorsurfaces, in combination with the positive internal pressure, results insignificantly larger forces on some components of the building envelopethan would be caused by external pressure alone. Therefore, thelikelihood of simultaneous occurrence of a positive internal pressureand a negative external pressure peak is of major importance in buildingdesign considerations.

Historically, damage to roof coverings and rooftop equipment is theleading cause of building performance problems during hurricanes. Rainsaccompanying a hurricane can cause water to enter buildings throughdamaged roofs, resulting in major damage to the contents and interior.For example, unless quick action is taken to dry a building, mold bloomcan quickly occur in the hot, humid Florida climate. Drying of buildingswas hampered after Hurricane Charley in 2004 by the lack of electricalpower to run fans and dehumidifiers. These damages frequently are morecostly than the roof damages themselves. Water leakage can also disruptthe functioning of critical and essential facilities and weaken ceilingsand cause them to collapse. Further, ceiling collapse can cause injuryto occupants.

SUMMARY

A roof panel may include a panel formed of concrete having an elongatedprofile with a top surface and a bottom surface. The top surface mayinclude a series of alternating ridges and valleys extending between thefirst and second edges and defining a corrugated surface. A first layerof reinforcing material may be disposed along, and spaced inwardly from,a first surface of the roof panel, and an optional second layer ofreinforcing material may be disposed along, and spaced inwardly from, asecond surface of the roof panel. The first layer of reinforcingmaterial may be spaced from the second layer of reinforcing material.The reinforcing material in some aspects may be formed offiber-reinforced polymer (FRP) mesh, made with carbon fibers or glassfibers, for example. The roof panel may include one or more elongatedribs having a thickness greater than adjacent portions of the roofpanel.

According to another aspect, a roof system may include a roof panel thatis supported by first and second support members at opposite ends of theroof panel. The roof panel may be secured to the support members byfasteners arranged for connection together after the roof panel is fullyformed.

According to a further aspect, a method of forming a roof system for abuilding may include forming the roof panel separate from the supportmembers, transporting the roof panel to the support members afterforming, and securing the roof panel to the support members withfasteners.

In still a further aspect, a method of forming a roof system for abuilding may include forming the roof panel in-situ at the buildingsite.

Other aspects and advantages will become apparent upon consideration ofthe following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of a building including a roof systemaccording to some aspects of the present disclosure;

FIG. 2 is an isometric view of a roof panel usable in the roof system ofFIG. 1;

FIG. 3 is an enlarged end view of the roof panel in the detail areamarked in FIG. 2 showing details of the cross-sectional profile of theroof panel;

FIGS. 4-5 are detailed end views of cross-sectional profiles similar toFIG. 3 of additional arrangements of the roof panel.

FIG. 6 is an end view of a cross-sectional profile of another exemplaryroof panel.

FIG. 7 is a cross-sectional view of another embodiment of end portionsof two roof panels.

FIG. 8 illustrates the roof panels of FIG. 7 connected with one another.

FIG. 9 is a side view of a roof ridge and one embodiment of a roofpanel-to-roof panel connection.

FIG. 10 is a side view of a roof panel-to-building wall connection.

FIG. 11 is a side cross-sectional view of another exemplary roof panel.

FIG. 12 is a cross-sectional side view of one embodiment of a concretestructure.

FIG. 13 is a cross-sectional side view of another embodiment of aconcrete structure.

FIG. 14 is a cross-sectional side view of yet another embodiment of aconcrete structure.

DETAILED DESCRIPTION

Turning now to the drawings, FIG. 1 illustrates a roof system 10constructed according to principles of the present disclosure andincorporated in a structure, such as building 12, to provide protectionof an interior of the building from external elements, such as wind,rain, heat, cold, dirt, and debris. The roof system 10 comprises one ormore roof panels 14 formed of concrete according to principles of thepresent disclosure, which, in some arrangements, may provide improvedresistance to failure under high wind loads, such as during hurricanes,over roof systems currently commonly used for buildings, such as singlefamily residences.

The roof panels 14 are coupled together at joints 23. The roof panels 14are supported by a first support 16, such as a load bearing wall, beam,or lintel, and a second support 18, such as a support beam, ridge beam,girder, or lintel. Preferably, each of the supports 16, 18 provides aplurality of support points for each roof panel 14 where the panel isdirectly supported by the support point, either with or without anintermediate structure, such as an intermediate layer of caulk or abearing plate or the like, disposed there between. In a some preferredarrangements, each support 16, 18 provides a linear or curvilinearsupport surface across an entire width or length of the roof panel 14,such as the top of the load bearing wall 16, a lintel, a roof truss,beam, girder, etc. In other arrangements, one or more of the supports16, 18 may provide a plurality of spaced apart support surfaces that donot span the entire width or length of the roof panel 14, such as spacedapart bearing pads or columns.

The roof system 14 may optionally include one or more roof trusses 20and/or gables 22 as in standard A-frame residential home construction.However one possible benefit of the roof panel 14 is the versatility toprovide roof systems in a pitched roof or sloped roof without the use ofsupporting roof trusses such as trusses 20 extending between the walland the ridge beam given that the roof panels themselves providestructural support as will be explained further below.

FIG. 2 depicts one exemplary roof panel 14. The roof panel 14 is in theshape of a generally planar panel formed of concrete having top surface24 and a bottom surface or second surface 26, each of the top and bottomsurfaces 24, 26 having a length and a width, wherein the length extendsalong a longitudinal axis 28 from a first axial end 30 to a second axialend 32, and the width extends laterally to the longitudinal axis from afirst lateral edge 34 to a second lateral edge 36. The term “generallyplanar” is used to mean that the large-scale shape of the panel isplanar, although as described below, the surface may have variousnon-planar features or architectural features, such as ribs, corrugatedridges and valleys, and/or other surface features that are relativelysmall in relation to the overall outer peripheral dimensions of thepanel. However, the roof panel 14 is not limited to generally planararrangements and may be curved or angled as may be needed for differentapplications or designs.

In one embodiment, the roof panel 14 has an elongated cross-sectionalprofile 17, which extends from the first axial end 30 to the secondaxial end 32. A first exemplary profile section 3 is illustrated indetail in FIG. 3. The top or first surface 24 of the roof panel 14extends from the first lateral edge 34 to the second lateral edge 36 andhas an undulating surface, such as a corrugated surface formed by aplurality of alternating and axially aligned elongated ridges 40 andvalleys 42. In another embodiment, the ridges 40 can be more triangularin shape or other geometric shape as compared to that shown in FIG. 2.The ridges 40 and valleys 42 alternate laterally from the first lateraledge 34 to the second lateral edge 36, whereby, other than at thelateral edges 34 and 36, each valley 42 is disposed between and adjacentto two ridges 40, and each ridge 40 is disposed between and adjacent totwo valleys 42. The alternating ridges 40 and valleys 42 preferablyextend completely from the first lateral edge 34 to the second lateraledge 36, as shown in FIG. 2; however, in some arrangements, the topsurface 24 may include flat sections interspersed among the ridges andvalleys or other patterns. Each of the ridges 40 and valleys 42 has anaxis extending from the first axial end 30 to the second axial end 32.Preferably the ridges and valleys are arranged parallel with each otherand to the longitudinal axis 28 of the roof panel 14.

FIGS. 2 and 3 show the top surface 24 undulating in a generallysinusoidal shape in the width direction; however, other undulationshapes, such as box-shaped, semi-circular, arched, polygonal, etc., mayalso be used. The undulating roof panel can also be referred to as anarchitectural roof panel since it allows the roof panel to have somearchitectural or ornamental design aspect. As explained in furtherdetail below, the bottom surface or second surface 26 may be corrugated,such as to match at least some portions of the top surface,un-corrugated, such as being flat or substantially flat, or include acombination of corrugated areas and un-corrugated areas. The bottomsurface 26 can also be made flat by adding moisture protection materialand/or insulation material to hollow regions 48 shown in FIG. 3.

Reinforcing material having a higher ductility and tensile strength thanconcrete to provide improved bending strength, as is generallyunderstood in the art, is embedded within the concrete of the panel.According to principles of the present disclosure, in one embodiment,the roof panel 14 includes a first reinforcement layer 50 proximate thetop surface 24 and a second reinforcement layer 52 proximate the bottomsurface 36.

As best seen in FIG. 3, in one embodiment, the first reinforcement layer50 is spaced inwardly from the top surface 24 and follows the topsurface, such as by being generally parallel with the top surface withinnormal construction placement tolerances. Similarly, the secondreinforcement layer 52 is spaced inwardly from the bottom surface 26 andis generally parallel with the bottom surface. Preferably, the firstreinforcement layer 50 is spaced from the second reinforcement layer 52across substantially the entire width and length of the roof panel 14.In one embodiment, reinforcement layers 50, 52 are formed of afiber-reinforced polymer (FRP) mesh, such as a carbon FRP mesh or aglass FRP mesh and spaced about 0.25 inch from their respective top orbottom surfaces 24, 26, other depths can be utilized for differentapplications and/or thickness of the FRP mesh. Other reinforcingmaterials besides FRP mesh, such as FRP rebar or steel rebar, mayadditionally or alternatively be incorporated into the first and/orsecond reinforcement layers 50, 52. Each of the reinforcement layers 50,52 preferably extends substantially the entire length and width of theroof panel 14, although in some embodiments the reinforcement layers 50,52 may be found only in certain areas within the roof panel 14. As anillustrative example, in other embodiments, the top or bottomreinforcement layers 50, 52 may be placed along substantially the entirelength and width of the roof panel 14, but the other reinforcement layermay not be found at all, or placed selectively along portions of theroof panel, for example, just along portions of the ridges 40.

FRP mesh reinforcement may provide advantages over other types ofreinforcement, such as steel mesh, rebars, or simple reinforcementfibers mixed into the concrete that are not formed as a mesh. Forexample, FRP mesh may avoid problems with corrosion experienced withsteel mesh and rebars while providing more aggregate structural tensilestrength over the use of fiber reinforcement that is simply mixed inuniformly in the concrete. FRP mesh also may provide more strength withless space and provide for easier forming in concrete molds, therebyallowing the overall thickness of the roof panel 14 to be minimized.

The roof panel 14 includes one or more structural ribs 46 extendinglongitudinally from the first axial end 30 to the second axial end 32 ofthe roof panel 14. The structural ribs 46 in some arrangements providestructural integrity for increased bending strength between the axialends 30 and 32 and/or provide increased shear strength at supportpoints, such as at support points on the wall and support beam in thebuilding 12. In some applications, these structural ribs allow the roofpanel 14 not to require the use of support trusses 20 from the wall toridge line of a building.

In one embodiment, each structural rib 46 is formed by filling in ahollow ridge portion 48 found underneath the ridges 40 and part of thearchitectural feature of the roof panel. Structural ribs 46 preferablycannot be noticed if one is looking at the top surface 24 of the roofpanel (see for example FIG. 2), thereby allowing the roof panel 14 tohave added structural strength while maintaining its aesthetic appealwhen covering a building, which is often important in residentialapplications. Adding the structural rib 46 to an architectural feature(hollow ridge area found underneath ridge) of the roof panel 14 allowsthe roof panel to look aesthetically pleasing when looking, for example,at the top surface of the roof panel, while adding structural strengthto the roof panel 14.

Each structural rib 46 is defined by a thicker portion of the roof panel14 than the adjacent portions of the roof panel. Thus, the roof panel 14has a first thickness in regions between adjacent ribs 46 and a secondthickness at the rib 46 that is larger than the first thickness.

In the arrangement shown in FIG. 3, each structural rib 46 is defined bya portion of the bottom surface 26 that extends generally straightbetween adjacent valleys 42 across a ridge 40, thereby forming a solidridge 40 a. In contrast, the ridges 40 where there is no structural rib46 are hollow ridges 40 b, in that the bottom surface 26 generallyfollows the shape of the top surface 24 to form a hollow region 48opposite the corresponding ridge 40 b. The ribs 46 are not limited tothe solid ridge form shown. For example, in some arrangements astructural rib 46 does not completely fill the area (hollow region 48)under a particular rib 40 a, and in other arrangements, the rib 46projects outwardly from the area under the rib 40 a beyond the surfaceof the adjacent valleys 42. In still other arrangements, the ribs mayhave different profiles, such as a rectangular profile, polygonalprofile, I-profile, C-profile. In additional arrangements, a rib 46 islocated along the bottom surface 26 opposite a valley 42. In yet afurther arrangement, a structural rib 46 is disposed on the top surface24 and aligned longitudinally along the length of the roof panel 14. Ina further embodiment, the roof panel 14 includes ribs 46 as describedherein disposed along the bottom surface 26 and along some of thevalleys on the top surface 24, such as valley 42 a.

The undulations forming the corrugated form in the top and/or bottomsurfaces 24, 26 may be in the shape of the sinusoidal-type surfacedepicted in FIGS. 2-4 and 6, semi-circular barrel-type surface as shownin FIG. 5, or other undulating elongated axial shapes, such as polygonalshapes or other curvilinear shapes. In the exemplary arrangement of FIG.3, the roof panel 14 has a generally sinusoidal, corrugatedcross-sectional profile 17 a, wherein the profile has alternating ridges40 and valleys 42, as previously described, with a generally constantthickness, and a plurality of the ribs 46 spaced apart along the widthof the roof panel 14. The bottom surface 26 undulates with the topsurface 24 between adjacent pairs of ribs 46, and is preferablygenerally parallel with the top surface, such that the ridges 40 andvalleys 42 between adjacent pairs of ribs 46 have a substantiallyconstant thickness, i.e., the dimension between the top surface 24 andthe bottom surface 26, between the top surface 24 and the bottom surface26.

In the arrangement of FIG. 3, the roof panel 14 has two hollow ridges 40b disposed between two adjacent structural ribs 46 or solid ridges 40 a,and this pattern is repeated a number of times across the width of theroof panel 14. However, other sequences of ribs and hollow ridges 40 bmay also be used, some of which are exemplified hereinafter.

In one arrangement, the elongated profile 17 is substantially constantalong the length of the roof panel 14 between the first and second axialends 30, 32, which may facilitate rapid or scalable manufacture byconcrete extrusion techniques. However, additional structures may beadded to the roof panel 14 and/or certain anomalies, such as cut-outsfor mechanical runs or electrical ducts, fasteners, and the like may belocated along the panel without substantially altering the overallgeneral profile between the ends 30, 32. Additional structural members,such as transverse cross bracing may also be included along the roofpanel 14 within the general principles of the disclosure.

The concrete may be any type of concrete suitable for roofing use andthat can provide adequate structural integrity for a given structuraldesign. In one preferred arrangement, the concrete comprises standardhigh strength or low strength Portland cement combined with one or moreaggregates, such as sand, crushed stone, gravel, and/or light weightaggregates, such as Perlite™, synthetic materials, and optionally otheradmixtures known or future developed in the art for providing variousdesirable qualities to a particular concrete, such as improvedworkability, structural strength, etc.

The roof panel 14 may have any dimensions practicable for providingsufficient structural integrity for a given application. It isanticipated that in some instances the roof panel 14 may have anunsupported span of ten feet (304.8 cm) or more from the first end 30 tothe second end 32, however the roof panel 14 may be formed much longerthan ten feet and have one or more intermediate support locationsbetween the first and second ends 30, 32. The roof panel 14 may have athickness at least between about 1 inch (2.54 cm) and about 6 inches(15.24 cm) or more depending on the particular application, span, etc.The roof panel 14 may have almost any width and any number ofundulations as would be practicable for various constructionconstraints, such as transportability and hoisting limitations, as wellas aesthetic implications. The roof panels 14 may also be dyed in aparticular color to make them more appealing, especially in residentialapplications. It is anticipated that roof panels 14 may have generally awidth of between approximately 2 feet (60.96 cm) and 20 feet (609.6 cm),more preferably between about 6 feet (182.88 cm) and seven feet (213.36cm) with adjacent ridges 40 being spaced at approximately 10 inches(25.4 cm) on center and adjacent ribs 46 being spaced at approximately40 inches (101.60 cm) on center. However, an almost infinite variety oflengths, widths, and thicknesses could be possible within the principlesof the disclosure and the dimensions provided are exemplary only.

Returning to the roof system 10 as shown in FIG. 1, the building 12 maycomprise any structure for which a roof system may be useful to protectpeople or goods from one or more of the various external elements. Forexample, although the building 12 is depicted as a common residentialhouse, the building may comprise practically any type of buildingstructure, such as a warehouse, high rise building, low rise building,commercial or manufacturing facility, garage, shed, car port, stadium,and the like. In preferred anticipated uses, the roof system 10 isparticularly well suited for use in low-rise buildings generally no morethan three or four stories tall, although the roof system is not limitedto use with low-rise buildings.

In the instant example, the roof system 14 is depicted as a commonpitched roof arrangement, such as a standard A-frame arrangement, forease of reference. However, it will be apparent to one of ordinaryskill, that the roof system 10 may be readily adapted for any type ofroof wherein a panel spans and is supported by two or more spaced apartsupports, such as flat roof systems, sloped roof systems, and the like.

In a preferred arrangement, the roof panels 14 are pre-fabricated awayfrom the building 12, for example by concrete extrusion or by the use ofmolds, and transported to the building after being fully formed andsecured to the supports with fasteners, such as bolts, rivets, weldedtogether steel plates, and the like. In manufacture, the roof panels canbe molded a predefined length and then cut to size based on a particularproject, or molded to the exact lengths required for a particularproject. The reinforcement layers 50, 52 can be placed and supportedinside the mold using support members so that they are correctly spacedfrom the top and bottom surfaces 24, 26 of the roof panels 14 usingknown techniques. In other circumstances, the roof panels 14 may be castin place at the building 12 directly on to the supports or as integralparts of the supports using known or future developed cast-in-placeforming techniques, for example to eliminate the joints 23. Jointconfigurations such as tongue and groove joints, pin joints (such asthose used in the apex of three-hinged arch configurations), etc. are tobe used for fastening pre-cast panels to the supports or to each other.

Turning now to FIGS. 4-6, alternative or additional profiles 17 b-d forthe roof panel 14 are shown as exemplary of just some of many possiblevariations within the principles of the present disclosure. It is to beunderstood that the roof panel 14 may include one or more of any of thevarious profiles 17 a-d disclosed herein, either singly or in differentcombinations, and that the principles of the present disclosure are notlimited to the example profiles detailed herein.

FIG. 4 shows a corrugated profile 17 b for the roof panel 14 that has noribs 46. In this arrangement, each of the top and bottom surfaces 24, 26undulates to form alternating ridges 40 and valleys 42, and hollowregions 48. The undulations of the top surface generally correspond withthe undulations of the bottom surface. In one embodiment, the roof panel14 may have a substantially constant thickness across the entireprofile, with the top surface 24 being substantially parallel with thebottom surface 26. In the depicted arrangement, the undulations aregenerally sinusoidal in shape, but other shapes may also be used asdiscussed elsewhere. First and second reinforcement layers 50, 52 aredisposed along the top and bottom surfaces 24, 26 as previouslydescribed herein.

FIG. 5 shows an exemplary profile 17 c for the roof panel 14 having aso-called “barrel ridges,” in which the top surface 24 includes aplurality of ridges 40 in the shape of arcuate humps and valleys 42 inthe shape of flat spaces defined between adjacent ones of the ridges 40.In this arrangement, the bottom surface 26 is substantially flat orplanar, whereby each ridge 40 is a solid ridge forming a structural rib46; however in other arrangements one or more of the ridges 40 may be inthe form of a hollow ridge (e.g., hollow ridge 48 in FIG. 3) asdescribed previously or the bottom surface may have a larger radiuscurvature extending across several ridges 40 and valleys 42, forexample. First and second reinforcement layers 50, 52 are disposed alongthe top and bottom surfaces 24, 26, in this embodiment reinforcementlayer 52 is substantially flat paralleling the substantially flat natureof bottom surface 26.

FIG. 6 shows a further exemplary profile 17 d for the roof panel 14 thatis generally similar to the profile 17 a shown in FIG. 3, except thatthe ridges 40 and valleys are flatter, i.e., the ridge to valley height,h, versus the on-center distance, d, between adjacent ridges and/orvalleys is comparatively less, as compared with the form of the profileshown in FIG. 3.

Further, adjacent roof panels 14 may be connected to each other withfasteners along a joint 23. Caulk or a waterproofing membrane may beapplied to the roof system 10 to prevent ingress of water along thejoint 23. Alternatively, the ends of adjoining roof panels 14 can bedesigned to provide joint and groove or similar types of connectionsbetween the adjacent roof panels 14. The joint 23 may be provided withor sealed with a waterproofing material such as rubber compound toprevent water from penetrating through the joints 23.

FIG. 7 shows a side view of portions of end sections 34, 36 of a firstroof panel 704 having a tongue 706 and a second roof panel 702 having agroove 708 used for receiving the tongue 706. The tongue 706 and groove708 can be angled to work with the pitch of the roof application inquestion. The two roof panels 702, 704 can be interconnected togetherusing the tongue and groove design in order to provide for a goodconnection between the roof panels 702,704. A concrete adhesive and/orwater protectant material such as impervious rubber membrane material(e.g., AMES Blue Max™ Liquid Rubber) as known in the art can be addedprior to joining the two roof panels 702, 704 together in order toprovide for a stronger bond between the two roof panels 702, 704 andwater intrusion protection. The two roof panels 702, 704 are shownjoined together in FIG. 8. The length of the roof panels 702, 704 can bedesigned for any required length depending on the building designrequirements. In order to provide further strength to the roof panels702, 704, Glass Fiber Reinforced Polymer (GFRP) rebar 710 are addedsubstantially along the length of the roof panels 710, 712. AlthoughGFRP rebar is preferred given its lighter weight, steel rebar can alsobe used in alternative applications. The GFRP rebar 710 is introduced inproximity to the first and second reinforcement layers 50, 52. Inmanufacture, the GFRP rebar 710 can be tied to the reinforcement layers50, 52 inside the mold using wire or plastic tie wraps to situate themin place prior to pouring the cement/concrete mix into the mold.

Referring now to FIG. 9, one embodiment of a roof ridge roof panel toroof panel connection technique is shown. In this embodiment, roof panel902 is connected to roof panel 904 at the roof ridge using a bottomridge component 906 and a top ridge component 908. In one embodiment,the bottom and top ridge components 904, 906 can be made from FRP havingan appropriate thickness to support the roof panels 902, 904 and otherroof panels along the particular ridge. The top ridge component 908 canhave a length that complements the length of the ridge.

During installation, the bottom ridge component 906 is connected to thefirst roof panel 902 using FRP bolt 910 and nuts 912, 914, alternativelystainless steel bolts/nuts or other fasteners can be used. In order tomake the installation of the roof panels easier, the bottom ridgecomponent 906 can be installed to roof panel 902 and the roof panelopposite it along the ridge line, roof panel 904 can then be presentedto roof panel 902 and fastened to the same bottom ridge component 906 sothat the opposite roof panels can help support each other. A watersealer such as liquid rubber can be placed between the roof panels 902,904 at the top of the ridge. The top ridge component 906 can then beconnected using the upper nuts 914. The upper nuts 914 can then becovered with liquid rubber or other material for water proofing. Otherroof panels can then be introduced in similar fashion until the entireroof opening is covered. Although the bottom and top ridge components904, 906 are shown substantially flat in cross-section, they can beundulated to match the shape along the ridge line of the roof panels.During or after the connection of the bottom and top ridge components904, 906, a water sealant material can be added to protect against waterintrusion.

In FIG. 10, there is shown a roof-to-wall connection in accordance withan embodiment of the disclosure. In this embodiment, the roof-to-wallconnection includes securing a section of 2×4 inch (or other size,depending on the design) roof wood member 1004 to the masonry block(e.g., CBS block) 1010 using a steel strap 1006 embedded in the masonryblock wall 1010 which is nailed or secured in other fashion to the 2×4roof wood member 1004. The end of the roof wood member 1004 is angled inorder to accept the section of roof panel 1012 that will rest on top ofit. An FRP rod 1008 embedded into the masonry wall 1010 and having athreaded end section is used to secure the roof panel 1012 to the wall1010, using an FRP nut 1002. In construction, the FRP rod 1008 and steelstrap 1006 are embedded in the top masonry block and concrete is addedto the wall 1010 to secure the rod 1008 and strap 1006. The FRP rod 1008connects through an aperture found in the roof panel 1012. The number ofFRP rods needed per roof panel will depend on the particular width andsize of the roof panel, pitch of roof, etc.

Referring now to FIG. 11, a side cross-sectional view of a roof panel1102 is illustrated. The roof panel 1102 includes a water proofingbarrier 1104 and an insulation barrier 1106 added to the roof panel1102. The water proofing barrier 1104 is preferably disposed on a bottomsurface of the roof panel 1102. The insulation barrier 1106 ispreferably disposed on a bottom side of the water proofing barrier 1104.The water proofing barrier 1104 and insulation barrier 1106 are addedby, for example, spraying or using other well-known depositingtechniques onto the roof panel 1102 at the bottom surface. In thisexample, the bottom surface of the insulation layer 1106 is shownsubstantially flat once the insulation barrier 1106 and water proofingbarrier 1104 are applied. The water proofing barrier 1104 can be formedof impervious rubber membrane (e.g., liquid rubber material) that canadhere to the roof panel 1102 and can be either introduced into the moldduring production of the roof panel or applied after the roof panelcomes out of the mold. The insulation barrier 1106 can be formed of anyone of a number of known insulation material that can be applied to theroof panel 1102 (e.g., by pouring into mold, spray-on, etc.). Asillustrated in FIG. 11, the roof panel 1102 provides a simple method ofproviding high-wind resistance roofing that also provides water andsound protection in one roof panel.

The disclosed roof system may in many instances provide one or morebenefits over currently available roofing systems. For example, the roofsystem can be designed to meet minimum requirements in building codes inhurricane-prone regions, such as the Miami-Dade County Building Code,for example, and has a high structural integrity as compared to commonwood roof systems. The roof system may provide sufficient ductility toprevent or substantially reduce the risk of sudden catastrophiccollapse. Use of FRP reinforcing structure in lieu of or in addition toconventional steel reinforcement reduces or eliminates degradation ofductility strength caused by corrosion. The roof system is readilyadaptable to have higher fire resistance than common wood roof systemsusing wood trusses and plywood sheathing. The roof system can bepre-fabricated or cast-in-place depending on the requirements of aparticular construction project.

FIG. 12 illustrates an exemplary profile of another embodiment that hasa first or outer surface 1214 that is substantially flat and a second orinterior surface 1216 that is substantially flat after insulation 1212is added to concrete structure 1206. This embodiment can be useful inapplications such as building structures for commercial and industrialbuildings that use either flat or sloped roofs designs or a combination,as well as for wall panels for forming the walls of a building. Foamblocks 1208, and FRP or regular steel rebar 1204 may be located withinthe concrete structure 1206 and run along the length of the structure.The length and width of the structure can vary based on the applicationbeing designed for. FRP mesh 1202 runs along the width and length of thestructure in proximity to the outer surface 1214 and the interiorsurface 1216. The FRP mesh 1202 may be embedded within the concretestructure 1206 at a predetermined depth from the outer and innersurfaces 1214, 1216 and may cover most of the surface areas of thesesurfaces, similar to some of the embodiments previously discussed. Inanother embodiment, the depth of the FRP mesh can vary from the surfaceof the structure in some sections depending on particular designrequirements. In other embodiments, only one mesh may be located inproximity to either the outer or inner surfaces 1214, 1216, as opposedto being located along both surfaces.

In the embodiment of FIG. 12, the concrete structure has a substantiallyflat surface on the outer surface 1214 while the interior surface 1216undulates. Insulation 1212, such as spray-on foam insulation or othertypes of insulation, may fill the cavities created by the undulatingconcrete structure of the interior surface 1216. The foam blocks 1208and the insulation 1212 provide a concrete panel that is strong andhighly insulating. Although not illustrated in FIG. 12, in analternative embodiment, the panel may further include electrical/waterlines which may for example be embedded within the insulation 1212 foundalong the inner surface 1216 of the structure.

The concrete used to form the structure may be, for example, a lightweight concrete in order to keep the weight of the overall structuredown. The panels may have interlocking ends allowing them to beinterconnected as previously discussed in association with FIG. 7. Ifused for a roof application the panels may be connected as illustratedin FIG. 9, or the panels may be connected in a flat (horizontal)condition, thereby creating a flat roof interconnected to walls of thebuilding similar to the earlier discussion related to FIG. 10, exceptthe panels may be substantially horizontal on top of the walls. Ifpanels are interconnected, a waterproofing barrier can be appliedbetween the interconnections to keep water from seeping between thepanels. In some applications, a whole wall or roof may be formed as oneintegral member that is cast on site using known cast-in-placetechniques. If used in a roofing application, the outer surface 1214 mayfurther include a roof membrane (not shown).

Referring now to FIG. 13, another embodiment of a concrete member 1314is illustrated that is made preferably of lightweight concrete 1316.FIG. 13 illustrates a side view along the width of the structure. Thewidth, length and height of the structure may vary based on designrequirements such as span and strength requirements, etc. The concretemember 1314 may be similar to those previously described in relation toFIG. 3-12. The ends of the panel illustrated in FIG. 13 may include oneend section 1318 having a tongue and the other end section 1320 having agroove so that other panels may be interconnected together, althoughother types of interconnection techniques may be utilized. In FIG. 13,two panels are interconnected with the center area formed by theinterconnection of the two panels forming an embedded beam 1308 thatincludes preferably FRP rebar 1310, although steel rebar may be utilizedfor some applications. FRP mesh 1304 and 1306 may be embedded inproximity to the top and bottom surfaces of the concrete member 1314 andmay cover most of the area along the length and width of the structureat a predetermined depth from the outer and inner surfaces. Insulation1312 may be located on both sides of the structure providing improvedinsulation capability for the structure. The insulation may be moldedinto or sprayed onto the structure, or added using other well-knowntechniques. On the outer (top) surface of the structure, an optionalmembrane 1302 may be added. The membrane in one embodiment may be astandard roof membrane, while in another embodiment membrane 1302 maycomprise a photovoltaic membrane that forms a solar panel that cancollect solar energy.

FIG. 14 illustrates a profile of another embodiment that may includeembedded beam portions 1404 that have FRP rebar 1402 along the length ofthe structure for added reinforcement so that the structure can span alonger length and can be stronger than panels without FRP rebar.Optional insulation 1406 may be included in this embodiment for addedinsulation capability of the structure. Similar to some of the otherembodiments, FRP mesh 1408, 1410 may be located in proximity to theupper and lower surfaces of the light weight concrete shell 1412 inorder to reinforce the concrete shell using very lightweight material.

The estimated cost of the structures discussed is comparable to the costof conventional roofing and wall systems, and may include prefabricatedor cast-in-place panels with various shapes and configurationsaddressing the architectural and structural requirements for aparticular design. Tests have found that the disclosed structures canwithstand winds up to 200 mph, as opposed to traditional multiple layerroof systems (i.e., metal roofs) that delaminate and break apart underextreme wind conditions. In areas of the United States where high windevents such as hurricanes occur, the disclosed structures minimize thenegative effects caused by such events.

The disclosed structures provide high structural integrity at low cost.As previously mentioned, in some designs the structures can supportpre-installed wiring and utility connections. Additionally, some designsmay include pre-attached insulation to accomplish higher energy ratingand sound proofing. The disclosed structures have high ductility andprovide higher fire rating than existing systems. For areas wherecorrosion is a concern, if FRP alone of FRP and FRP rebar are used in adesign, the corrosion concerns can be reduced or eliminated whencompared to using steel reinforcement techniques, thereby reducingmaintenance and repair costs. The disclosed structures maintainaesthetic appeal by replicating architectural shapes of roofs such asflat roofs, flat roofs with pavers, flat roofs with the texture of lightweight concrete, barrel tile roofs, etc, while providing superiorstrength. Design features such as metal seam external geometries canalso be added to the outer surface of a design to make the externalsurface appear to look like a metal roof, etc.

According to some general principles of the present disclosure, aroofing system assembled in accordance with the teachings of one or moreof the examples disclosed herein may provide corrugated concrete panelsreinforced with high-performance fiber-reinforced polymer (FRP) meshthat when assembled are intended to provide improved resistance to wind,water, and/or debris when compared to currently known roofing systems,and preferably at a comparable cost with currently known roof systems.The disclosed structures may eliminate or at least significantly reducecommonly used roof sub-assemblies and components, such as roof trusses,sheathing, underlayment, and separate coverings, such as tiles,shingles, etc. In one preferred arrangement, the roof panels replicatethe shape and color of known so-called barrel tiles, i.e., roofing tilesin the shape of a segment of a barrel. In various arrangements, theroofing system may be used for new construction, i.e., construction of acompletely new building or structure, and/or for retrofitting a new roofsystem to an existing structure. According to additional principles ofthe present disclosure, a roof system as disclosed herein may be formedby forming the roof panel in-situ on first and second supports using amold, removing the mold once the roof panel has been formed, andsecuring the roof panel to each of the first and second support memberswith a plurality of fasteners.

In some aspects, the roof system and roof panels disclosed herein areuseful in many different applications, at least one of which includesuse as a hurricane resistant roof system in coastal low-rise buildings.The roof systems described herein however are not limited to anyparticular industrial usage and may be used in any other manners orapplication as desired.

Numerous modifications to the panel and panel system disclosed hereinwill be apparent to those skilled in the art in view of the foregoingdescription. Accordingly, this description is to be construed asillustrative only and is presented for the purpose of enabling thoseskilled in the art to make and use the invention and to teach the bestmode of carrying out same. The exclusive rights to all modificationswithin the scope of the appended claims are reserved.

We claim:
 1. A concrete component, comprising: a concrete panel having alength, a width, a first surface, and a second surface, said firstsurface having a surface area, said first surface and said secondsurface undulating in a sinusoidal shape across the width forming aseries of alternating ridges and valleys extending between first andsecond edges and defining a corrugated surface, a space beneath a ridgein the first surface forming a hollow ridge portion in the secondsurface, and some, but not all, of the hollow ridge portions in thesecond surface being filled in, forming a flat portion of the secondsurface, and each filled in hollow ridge portion forming at least onestructural rib on the second surface running the length of the concretepanel; and at least one layer of fiber reinforced polymer (FRP) meshembedded within the concrete panel and covering a substantial portion ofthe surface area of the first surface, the at least one layer of FRPbeing spaced inwardly from and parallel to the first surface, the atleast one layer of FRP extending along the entire length and width ofthe concrete panel.
 2. The concrete component of claim 1, wherein atleast of one of the first and second surfaces is partially covered withinsulation.
 3. The concrete component of claim 1, wherein the concretepanel undulates along the first surface and the second surface issubstantially flat.
 4. The concrete component of claim 3, whereininsulation is added into the undulations of the first surface.
 5. Theconcrete component of claim 3, wherein a membrane is coupled to thesecond surface.
 6. The concrete component of claim 5, wherein themembrane comprises a photovoltaic membrane.
 7. The concrete component ofclaim 1, wherein the embedded beam includes a foam block running along asubstantial portion of the length of the concrete panel.
 8. The concretecomponent of claim 1, wherein the structural rib further includes atleast one FRP rebar running along a substantial portion of the length ofthe concrete panel.
 9. The concrete component of claim 1, wherein theFRP mesh comprises at least one of carbon fibers and glass fibers.
 10. Aroof panel comprising: a concrete panel having a length, a width, and anelongated profile extending longitudinally from a first end to a secondend along the length, the elongated profile including a top surface anda bottom surface extending from a first edge to a second edge, the topsurface undulating in a sinusoidal shape across the width including aseries of alternating ridges and valleys extending between the first andsecond edges and defining a corrugated surface and the bottom surfaceundulating in a sinusoidal shape across the width and defining acorrugated surface, a space beneath a ridge in the top surface forming ahollow ridge portion in the bottom surface; and some, but not all, ofthe hollow ridge portions in the bottom surface being filled in, forminga flat portion of the bottom surface, and each filled in hollow ridgeportion forming at least one structural rib on the bottom surfacerunning the length of the concrete panel, the at least one structuralrib being incorporated into an architectural feature of the concretepanel.
 11. The roof panel of claim 10, wherein the at least onestructural rib is not visible when the roof panel is viewed from above.12. The architectural roof panel of claim 10, further comprising aninsulating barrier operatively coupled to the bottom surface.
 13. Thearchitectural roof panel of claim 10, further comprising a waterproofingbarrier operatively coupled to the bottom surface.
 14. The roof panel ofclaim 10, wherein the elongated profile comprises a plurality ofstructural ribs, each structural rib formed at a ridge.
 15. Anarchitectural roof panel for a truss free roof, the architectural roofpanel comprising: a concrete roof panel having a length and a width, atop surface, a bottom surface, the top surface and the bottom surfaceundulating in a sinusoidal shape across the width, the sinusoidal shapeforming a plurality of alternating and aligned elongated ridges andvalleys, a space beneath a ridge in the top surface forming a hollowridge portion in the bottom surface; some, but not all, of the hollowridge portions in the bottom surface being filled in, forming a flatportion of the bottom surface, and each filled in hollow ridge portionforming at least one structural rib; a first layer of reinforcementmaterial spaced inwardly from the top surface and inside of the roofpanel, the first layer of reinforcement material being oriented parallelto the top surface, the first layer of reinforcement material extendingalong the entire length and width of the concrete roof panel; and asecond layer of reinforcement material spaced inwardly from the bottomsurface and inside of the roof panel, the second layer of reinforcementmaterial being oriented parallel to the bottom surface, the second layerof reinforcement material extending along the entire length and width ofthe concrete roof panel; wherein the concrete roof panel providesstructural support.
 16. The roof panel of claim 10, wherein thestructural ribs formed by the filled in valleys on the bottom surfaceare formed at a regular interval.
 17. The roof panel of claim 16,wherein the regular interval is every third valley on the bottomsurface.